US20170314174A1 - Spunbond nonwoven fabric, nonwoven fabric layered body, medical clothing, drape, and melt blown nonwoven fabric - Google Patents

Spunbond nonwoven fabric, nonwoven fabric layered body, medical clothing, drape, and melt blown nonwoven fabric Download PDF

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Publication number
US20170314174A1
US20170314174A1 US15/521,939 US201515521939A US2017314174A1 US 20170314174 A1 US20170314174 A1 US 20170314174A1 US 201515521939 A US201515521939 A US 201515521939A US 2017314174 A1 US2017314174 A1 US 2017314174A1
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United States
Prior art keywords
nonwoven fabric
based polymer
ethylene
propylene
layered body
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Abandoned
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US15/521,939
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English (en)
Inventor
Taro Ichikawa
Yusuke SEKIOKA
Kuniaki Kawabe
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Mitsui Chemicals Inc
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Mitsui Chemicals Inc
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Assigned to MITSUI CHEMICALS, INC. reassignment MITSUI CHEMICALS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KAWABE, KUNIAKI, SEKIOKA, YUSUKE, ICHIKAWA, TARO
Publication of US20170314174A1 publication Critical patent/US20170314174A1/en
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
    • A41D13/12—Surgeons' or patients' gowns or dresses
    • A41D13/1209—Surgeons' gowns or dresses
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B46/00—Surgical drapes
    • A61B46/40—Drape material, e.g. laminates; Manufacture thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B32B5/265—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer
    • B32B5/266—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer next to one or more non-woven fabric layers
    • B32B5/268—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer next to one or more non-woven fabric layers characterised by at least one non-woven fabric layer that is a melt-blown fabric
    • B32B5/269—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer next to one or more non-woven fabric layers characterised by at least one non-woven fabric layer that is a melt-blown fabric characterised by at least one non-woven fabric layer that is a melt-blown fabric next to a non-woven fabric layer that is a spunbonded fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D04H3/011—Polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/16—Structural features of fibres, filaments or yarns e.g. wrapped, coiled, crimped or covered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2601/00—Upholstery

Definitions

  • the present invention relates to a spunbond nonwoven fabric, a nonwoven fabric layered body, a medical clothing, a drape, and a melt blown nonwoven fabric.
  • Nonwoven fabrics including propylene-based polymers are superior to nonwoven fabrics including ethylene-based polymers in that they have favorable spinnability, which facilitates thin fiber formation, and also have well-balanced strength, flexibility, and barrier performance.
  • nonwoven fabrics including propylene-based polymers have the above properties, they are widely used as medical materials, sanitary materials, absorbable items, packaging materials for various items, support materials, and backing materials.
  • long fiber nonwoven fabrics including propylene-based polymers obtained by a spunbond method or a melt blowing method have excellent comprehensive performance including lightweight property, uniformity, strength, flexibility, and barrier performance, and therefore, they are used for medical materials (e.g., surgical gowns, drapes, masks, sheets, and gauze).
  • a method of sterilization treatment include electron beam sterilization, gamma ray sterilization, gas sterilization, and steam sterilization.
  • a radioactive cobalt source is used for gamma ray sterilization, and an ethylene oxide gas is mainly used for gas sterilization, which are problematic in handling.
  • steam sterilization is problematic in certainty of sterilization. Therefore, in general, electron beam sterilization is considered to be an ideal method of safe and secure sterilization for a short period of time.
  • Document 1 Japanese Patent No. 2633936
  • a nonwoven fabric including a propylene-based polymer, which contains a long-chain fatty acid ester of 3,5-di-t-butyl-4-hydroxybenzoid acid.
  • Document 2 Japanese Patent Application Laid-Open (JP-A) No. H02-215848
  • a propylene-based resin composition having resistance to radiation which contains 95% by mass to 99.5% by mass of a propylene-based resin and 5% by mass to 0.5% by mass of an ethylene- ⁇ -olefin copolymer having a specific density and a specific number of side chain groups.
  • Document 3 Japanese National-Phase Publication (JP-A) No. 2001-508813
  • JP-A Japanese National-Phase Publication (JP-A) No. 2001-508813
  • JP-A Japanese National-Phase Publication (JP-A) No. 2010-509461
  • JP-A Japanese National-Phase Publication
  • JP-A Japanese National-Phase Publication No. 2001-508813
  • the above nonwoven fabric obtained by the technique disclosed in Japanese Patent No. 2633936 is prevented from having a decrease in strength after radiation irradiation, compared with a case in which a long-chain fatty acid ester compound of 3,5-di-t-butyl-4-hydroxybenzoic acid is not contained. Nevertheless, a decrease in strength after radiation irradiation is not sufficiently prevented to a satisfactory extent.
  • a resin composition containing a propylene-based polymer mixed with an ethylene-based polymer is used for nonwoven fabrics obtained by the techniques disclosed in JP-A No. H02-215848 and JP-A No. 2001-508813 described above.
  • such nonwoven fabrics have a large decrease in strength after radiation irradiation, and the melting point of the above polyethylene is low.
  • the nonwoven fabrics are heat layered with films and the layered bodies are treated by secondary processing to obtain medical drape materials, they have not been suitable.
  • nonwoven fabric obtained by the technique disclosed in International Publication WO2014/046070 described above, a mixture of a high-density polyethylene and a propylene-based polymer is used so that spinnability of the mixture is improved.
  • this nonwoven fabric contains fibers that are not sufficiently thinned and has high air permeability, and therefore, when it is layered as a medical material on a different member, it might result in lack of strength or barrier performance against blood or the like.
  • nonwoven fabric including fibers containing a propylene-based polymer, wherein strength is sufficiently high even after radiation sterilization treatment using an electron beam or the like, and even when the fiber diameter is reduced, aggravation of spinnability is prevented with the presence of an ethylene-based polymer.
  • An object of the invention is to provide a spunbond nonwoven fabric including fibers of a propylene-based polymer composition containing a propylene-based polymer, wherein sterilization treatment using an electron beam or the like is possible, strength is sufficiently high even after radiation sterilization treatment using an electron beam or the like, and even when the fiber diameter is reduced, aggravation of spinnability is prevented with the presence of an ethylene-based polymer, a nonwoven fabric layered body using the same, and medical clothing and drape using the same.
  • Another object of the invention is to provide a melt blown nonwoven fabric including fibers of a propylene-based polymer composition containing a propylene-based polymer and a stabilizer, which is excellent when used as a member of a nonwoven fabric layered body in terms of inter-layer adhesion strength and strength of the nonwoven fabric layered body.
  • a spunbond nonwoven fabric including fibers of a propylene-based polymer composition containing 100 parts by mass of a propylene-based polymer (A) and from 1 to 10 parts by mass of an ethylene-based polymer (B) having a density of from 0.93 g/cm 3 to 0.98 g/cm 3 ,
  • an air permeability of the spunbond nonwoven fabric that is measured in accordance with JIS L 1096 (2010) by a Frazier type air permeability tester at a flow rate corresponding to a pressure differential of 125 Pa is 500 cm 3 /cm 2 /s or less.
  • ⁇ 2> The spunbond nonwoven fabric according to ⁇ 1>, wherein the propylene-based polymer composition contains an ethylene-based polymer wax (C) having a weight-average molecular weight (Mw) of from 400 to 15,000.
  • Mw weight-average molecular weight
  • ⁇ 3> The spunbond nonwoven fabric according to ⁇ 2>, wherein the ethylene-based polymer wax (C) has a density of from 0.890 g/cm 3 to 0.980 g/cm 3 .
  • ⁇ 4> The spunbond nonwoven fabric according to ⁇ 2> or ⁇ 3>, wherein a content of the ethylene-based polymer wax (C) is from 0.1 parts by mass to less than 4 parts by mass with respect to 100 parts by mass of the propylene-based polymer (A).
  • ⁇ 5> The spunbond nonwoven fabric according to any one of ⁇ 1> to ⁇ 4>, wherein a melt flow rate (MFR) of the ethylene-based polymer (B) is from 2 g/10 minutes to 25 g/10 minutes.
  • MFR melt flow rate
  • ⁇ 6> The spunbond nonwoven fabric according to any one of ⁇ 1> to ⁇ 5>, which has a weight per unit area of from 5 g/m 2 to 50 g/m 2 .
  • ⁇ 7> The spunbond nonwoven fabric according to any one of ⁇ 1> to ⁇ 6>, wherein the mean fiber diameter of the fibers is 20 ⁇ m or less.
  • ⁇ 8> The spunbond nonwoven fabric according to any one of ⁇ 1> to ⁇ 7>, wherein a Strength INDEX after electron beam irradiation at an absorbed dose of 45 kGy is 10N or more.
  • the ethylene-based polymer composition contains an ethylene-based polymer (a) having a melt flow rate (MFR) of from 10 g/10 minutes to 250 g/10 minutes and an ethylene-based polymer wax (b) having a weight-average molecular weight (Mw) of from 400 to 15000 at a (a):(b) mass ratio of from 90:10 to 10:90.
  • MFR melt flow rate
  • Mw weight-average molecular weight
  • the nonwoven fabric layered body according to ⁇ 9> which includes a melt blown nonwoven fabric including fibers of a propylene-based polymer composition containing a propylene-based polymer (c) and at least one stabilizer selected from the group consisting of an organophosphorous compound, a hindered amine-based compound, and a phenolic compound.
  • a stabilizer selected from the group consisting of an organophosphorous compound, a hindered amine-based compound, and a phenolic compound.
  • the stabilizer contains the organophosphorous compound, the hindered amine-based compound, and the phenolic compound.
  • An article of medical clothing including the nonwoven fabric layered body according to any one of ⁇ 9> to ⁇ 13>.
  • a drape including the nonwoven fabric layered body according to any one of ⁇ 9> to ⁇ 13>.
  • a melt blown nonwoven fabric including fibers of a propylene-based polymer composition containing a propylene-based polymer (c) and at least one stabilizer selected from the group consisting of an organophosphorous compound, a hindered amine-based compound, and a phenolic compound.
  • a nonwoven fabric layered body including the melt blown nonwoven fabric according to ⁇ 16> or ⁇ 17>.
  • a spunbond nonwoven fabric including fibers of a propylene-based polymer composition containing a propylene-based polymer, wherein sterilization treatment using an electron beam or the like is possible, strength is sufficiently high even after radiation sterilization treatment using an electron beam or the like, and even when the fiber diameter is reduced, aggravation of spinnability due to the presence of an ethylene-based polymer is prevented, a nonwoven fabric layered body using the same, and an article of medical clothing and drape using the same can be provided.
  • melt blown nonwoven fabric including fibers of a propylene-based polymer composition containing a propylene-based polymer and a stabilizer, which is excellent when used as a member of a nonwoven fabric layered body in terms of inter-layer adhesion strength and strength of the nonwoven fabric layered body, can be provided.
  • Any numerical range expressed herein using the word “to” means a range of from a value corresponding to the minimum “to” a value corresponding to the maximum.
  • the spunbond nonwoven fabric of the invention includes fibers of a propylene-based polymer composition containing 100 parts by mass of a propylene-based polymer (A) and from 1 part by mass to 10 parts by mass of an ethylene-based polymer (B) having a density of from 0.93 g/cm 3 to 0.98 g/cm 3 .
  • air permeability determined by a JIS L 1096 (2010) Frazier type air permeability tester under flow rate conditions at a pressure differential of 125 Pa is 500 cm 3 /cm 2 /s or less.
  • the propylene-based polymer composition may further contain an ethylene-based polymer wax (C).
  • a spunbond nonwoven fabric including fibers of a propylene-based polymer composition containing a propylene-based polymer can be obtained, the spunbond nonwoven fabric having the above configuration, thereby realizing that sterilization treatment using an electron beam or the like is possible, strength is sufficiently high even after radiation sterilization treatment using an electron beam or the like, and even when the fiber diameter is reduced, aggravation of spinnability due to the presence of an ethylene-based polymer is prevented.
  • spunbond nonwoven fabric has a thin fiber diameter, and therefore, a nonwoven fabric layered body containing the spunbond nonwoven fabric can be preferably applied particularly to articles of medical clothing and drapes.
  • An propylene-based polymer (A) which is a major component of the propylene-based polymer composition used as a starting material of the spunbond nonwoven fabric of the invention is a polymer mainly containing propylene such as a propylene homopolymer or a copolymer of propylene and a small amount of an ⁇ -olefin.
  • Examples of an ⁇ -olefin that is copolymerized with propylene include ⁇ -olefins with 2 carbons or more (other than 3 carbons) and preferably with from 2 to 8 carbons (other than 3 carbons).
  • the propylene-based polymer (A) is preferably a propylene homopolymer or a propylene.ethylene random copolymer. Further, in a case in which heat resistance is prioritized, the propylene-based polymer (A) is preferably a propylene homopolymer.
  • the ethylene content in the propylene.ethylene random copolymer is favorably from 0.5 mol % to 10 mol %, preferably from 3 mol % to 8 mol %, and more preferably from 4 mol % to 7 mol %.
  • the melting point (Tm) of the propylene-based polymer (A) is not particularly limited; however, it is favorably in a range of 125° C. or more, preferably in a range of 140° C. or more, still more preferably in a range of 155° C. or more, and particularly preferably in a range of from 157° C. to 165° C.
  • the melt flow rate (MFR 230 : ASTM D-1238; 230° C.; load: 2160 g) of the propylene-based polymer (A) according to the invention is not particularly limited as long as melt spinning of the propylene-based polymer (A) is possible; however, it is preferably in a range of from 1 g/10 minutes to 500 g/10 minutes, more preferably in a range of from 5 g/10 minutes to 200 g/10 minutes, and still more preferably in a range of from 10 g/10 minutes to 100 g/10 minutes.
  • a ratio (Mw/Mn) of the weight-average molecular weight (Mw) and the number average molecular weight (Mn) for the propylene-based polymer (A) according to the invention is preferably from 1.5 to 5.0. It is more preferably in a range of from 1.5 to 4.5 in that good spinnability is achieved and fibers having remarkably excellent fiber strength can be obtained.
  • Mw and Mn can be determined by gel permeation chromatography (GPC) in accordance with a known method.
  • the density of the propylene-based polymer (A) according to the invention is preferably in a range of from 0.895 g/cm 3 to 0.915 g/cm 3 , more preferably in a range of from 0.900 g/cm 3 to 0.915 g/cm 3 , and still more preferably in a range of from 0.905 g/cm 3 to 0.910 g/cm 3 .
  • density is determined to be a value obtained by measurement in accordance with the density gradient method of JIS K7112.
  • An ethylene-based polymer (B) which is a component other than propylene-based polymer composition that is a starting material of the spunbond nonwoven fabric of the invention is an ethylene homopolymer or a copolymer of ethylene and a small amount of a different ⁇ -olefin.
  • the ethylene-based polymer (B) is specifically a polymer mainly containing ethylene such as a high pressure low-density polyethylene, a linear low-density polyethylene (so-called LLDPE), a middle-density polyethylene (so-called MDPE), or a high-density polyethylene (so-called HDPE).
  • Examples of a different ⁇ -olefin that is copolymerized with ethylene include ⁇ -olefins with from 3 to 20 carbons such as propylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, and 1-eicosene.
  • the ethylene-based polymer (B) may be an ethylene homopolymer or a mixture containing two or more types.
  • An ethylene-based polymer having a density within a range of from 0.93 g/cm 3 to 0.98 g/cm 3 is used for the ethylene-based polymer (B) according to the invention.
  • an ethylene-based polymer having a density within the above range is used, aggravation of spinnability is prevented, resulting in excellent strength of the obtained spunbond nonwoven fabric.
  • excellent temporal stability is also achieved.
  • the range of from 0.940 g/cm 3 to 0.980 g/cm 3 is preferable and the range of from 0.940 g/cm 3 to 0.975 g/cm 3 is still more preferable in that aggravation of spinnability is further prevented and the strength is further improved.
  • High-density polyethylene (HDPE) having a density within a range of from 0.950 g/cm 3 to 0.970 g/cm 3 is particularly preferable.
  • the melt flow rate (MFR 190 : ASTM D 1238; 190° C.; load: 2160 g) of the ethylene-based polymer (B) according to the invention is not particularly limited as long as melt spinning of the ethylene-based polymer (B) mixed with the propylene-based polymer (A) is possible.
  • the melt flow rate of the ethylene-based polymer (B) is preferably in a range of from 1 g/10 minutes to 50 g/10 minutes, more preferably in a range of from 2 g/10 minutes to 25 g/10 minutes, and still more preferably in a range of from 2 g/10 minutes to 10 g/10 minutes.
  • the melt flow rate of the ethylene-based polymer (B) is in the above range, spinnability of the propylene-based polymer composition is favorable, and the obtained spunbond nonwoven fabric has excellent strength. As these properties can be realized, the obtained spunbond nonwoven fabric can be favorably used particularly for medical materials and the like.
  • Polymers obtained by a variety of known manufacturing methods can be used for the ethylene-based polymer (B) according to the invention.
  • these polymers in a case in which an ethylene-based polymer obtained through polymerization using a metallocene-based catalyst is used, favorable spinnability of a propylene-based polymer composition is achieved, and favorable strength or the like of the obtained spunbond nonwoven fabric is achieved, which is preferable.
  • the propylene-based polymer composition that is a starting material of the spunbond nonwoven fabric of the invention may contain an ethylene-based polymer wax (C) in another embodiment of the invention, if necessary.
  • the ethylene-based polymer wax (C) has effects of improving dispersibility of the propylene-based polymer (A) and the ethylene-based polymer (B). This facilitates the further improvement of spinnability. Therefore, it is preferable for the propylene-based polymer composition to contain the ethylene-based polymer wax (C).
  • the ethylene-based polymer wax (C) according to the invention has a molecular weight lower than that of the ethylene-based polymer (B), meaning that the ethylene-based polymer wax (C) is a wax-type polymer.
  • the weight-average molecular weight (Mw) of the ethylene-based polymer wax (C) is preferably in a range of less than 15,000, more preferably in a range of less than 15,000, still more preferably in a range of 10,000 or less, still more preferably in a range of 6,000 or less, still more preferably in a range of less than 6,000, particularly preferably in a range of 5,000 or less, and most preferably in a range of 1,500 or less.
  • the lower limit thereof is preferably 400 or more and more preferably 1,000 or more.
  • the weight-average molecular weight (Mw) of the ethylene-based polymer wax (C) is within the above range, it is easier to improve spinnability of the propylene-based polymer composition, to reduce the fiber diameter, and to achieve temporal stability.
  • Mw weight-average molecular weight
  • a nonwoven fabric layered body is formed by layering the spunbond nonwoven fabric of the invention with, for example, a melt blown nonwoven fabric including an ethylene-based polymer, it is easier to achieve excellent inter-layer adhesiveness and strength, which is also preferable.
  • the weight-average molecular weight (Mw) of the ethylene-based polymer wax (C) according to the invention is a value obtained by GPC measurement under the following conditions.
  • the weight-average molecular weight is calculated in accordance with the conversion method described below using a calibration curve created with a commercially available standard monodisperse polystyrene.
  • Apparatus Alliance GPC 2000 gel permeation chromatograph (manufactured by Waters) Solvent: o-dichlorobenzene Column: TSKgel GMH6-HT ⁇ 2, TSKgel GMH6-HTL column ⁇ 2 (each manufactured by Tosoh Corporation) Flow rate: 1.0 mL/minute Sample: 0.15 mg/mL o-dichlorobenzene solution
  • the softening point of the ethylene-based polymer wax (C) according to the invention is preferably in a range of from 90° C. to 145° C., more preferably in a range of from 90° C. to 130° C., still more preferably in a range of from 100° C. to 120° C., and most preferably in a range of from 105° C. to 115° C.
  • the ethylene-based polymer wax (C) may be either an ethylene homopolymer or a copolymer of ethylene and an ⁇ -olefin with from 3 to 20 carbons.
  • the number of carbons for the ⁇ -olefin that is copolymerized with ethylene is more preferably from 3 to 8 carbons, still more preferably from 3 to 4 carbons, and particularly preferably 3 carbons.
  • ethylene-based polymer wax (C) functions as a compatibilizing agent for the propylene-based polymer (A) and the ethylene-based polymer (B), uniformity of the propylene-based polymer composition of the invention is enhanced, resulting in the improvement of the balance of properties such as spinnability and strength of a nonwoven fabric.
  • ethylene-based polymer wax In a case in which an ethylene homopolymer is used as the ethylene-based polymer wax (C), it has an excellent property of being kneaded with the ethylene-based polymer (B) and excellent spinnability.
  • the ethylene-based polymer wax may be used alone or a mixture of two or more types thereof may be used.
  • the ethylene-based polymer wax (C) according to the invention may be manufactured without particular limitation by any method such as a generally used manufacturing method of polymerization of a low-molecular-weight polymer or a method including reducing the molecular weight through heat degradation of a high-molecular-weight ethylene-based polymer.
  • the ethylene-based polymer wax (C) according to the invention may be purified by a method of solvent separation based on a difference in solubility in a solvent, distillation, or the like.
  • the ethylene-based polymer wax (C) is obtained by a generally used manufacturing method of polymerization of a low-molecular-weight polymer, it can be manufactured by a variety of known manufacturing methods such as a manufacturing method of polymerization using a Ziegler-Natta catalyst or a metallocene-based catalyst described in JP-A No. H08-239414 or International Publication WO2007/114102.
  • the density of the ethylene-based polymer wax (C) according to the invention is not particularly limited; however, it is preferably from 0.890 g/cm 3 to 0.980 g/cm 3 , more preferably 0.910 g/cm 3 or more, and still more preferably 0.920 g/cm 3 or more. It is also preferably 0.960 g/cm 3 or less and more preferably 0.950 g/cm 3 or less. When the ethylene-based polymer wax (C) having a density within the above range is used, the propylene-based polymer composition tends to have excellent spinnability.
  • nonwoven fabric layered body is formed by layering the spunbond nonwoven fabric of the invention with, for example, a melt blown nonwoven fabric including an ethylene-based polymer or the like, inter-layer adhesiveness or strength tends to be excellent, which is also preferable.
  • the difference between the density of the propylene-based polymer (A) and the density of the ethylene-based polymer wax (C) is not particularly limited; however, it is more preferably less than 0.35 g/cm 3 , particularly preferably less than 0.20 g/cm 3 , and most preferably less than 0.15 g/cm 3 .
  • the density difference is within the above range, favorable spinnability is achieved, thereby making it possible to improve nonwoven fabric properties such as strength. The reason for such improvement is unclear but it is probably as follows.
  • the difference between the density of the propylene-based polymer (A) and the density of the ethylene-based polymer wax (C) according to the invention is within the above range, it would facilitate dispersion of the ethylene-based polymer (B) in the propylene-based polymer (A) via the ethylene-based polymer wax (C). That is, it is considered that as the ethylene-based polymer wax (C) functions as a compatibilizing agent for the propylene-based polymer (A) and the ethylene-based polymer (B), uniformity of the propylene-based polymer composition of the invention is enhanced, resulting in the improvement of the balance of characteristics such as spinnability and strength of a nonwoven fabric.
  • the propylene-based polymer composition that is a starting material of the spunbond nonwoven fabric of the invention is a propylene-based polymer composition containing from 1 part by mass to 10 parts by mass of the ethylene-based polymer (B) with respect to 100 parts by mass of the propylene-based polymer (A).
  • it may be a propylene-based polymer composition containing from 1 part by mass to 10 parts by mass the ethylene-based polymer (B) with respect to 100 parts by mass of the propylene-based polymer (A) and further containing the ethylene-based polymer wax (C).
  • the content of the ethylene-based polymer (B) is preferably 2 parts by mass or more and more preferably 3 parts by mass or more. It is also preferably 9 parts by mass or less and more preferably 8 parts by mass or less.
  • a spunbond nonwoven fabric obtained using the propylene-based polymer composition according to the embodiment has excellent strength after radiation sterilization using an electron beam or the like when the content of the ethylene-based polymer (B) is 1 part by mass or more.
  • the content of the ethylene-based polymer (B) is 10 parts by mass or less, the propylene-based polymer composition has excellent spinnability.
  • the propylene-based polymer composition in the invention contains the ethylene-based polymer wax (C)
  • dispersibility of the propylene-based polymer (A) and the ethylene-based polymer (B) is improved as described above, which eventually facilitates further improvement of spinnability.
  • the content of the ethylene-based polymer wax (C) is preferably from 0.1 parts by mass to less than 4 parts by mass, more preferably from 0.5 parts by mass to 3 parts by mass, and still more preferably from 0.5 parts by mass to 2.5 parts by mass with respect to 100 parts by mass of the propylene-based polymer.
  • the following examples of conventionally known catalysts can be favorably used: a magnesium-bearing titanium catalyst described in JP-A No. S57-63310, JP-A No. S58-83006, JP-A No. H03-706, Japanese Patent No. 3476793, JP-A No. H04-218508, or JP-A No. 2003-105022; a metallocene catalyst described in International Publication WO2001/53369, International Publication WO2001/27124, JP-A No. H03-193796, or JP-A No. H02-41303.
  • the propylene-based polymer composition according to the invention may optionally contain other components other than the propylene-based polymer (A) and the ethylene-based polymer (B) within the range not impairing the objectives of the invention, if necessary. These components can be mixed using a variety of known methods.
  • Examples of other components that can be optionally used, if necessary, include a variety of the following additives: other polymers; colorants; antioxidants such as phosphorous or phenolic antioxidants; weathering stabilizers such as benzotriazole-based weathering stabilizers; light resistance stabilizers such as hindered amine-based light resistance stabilizers; antiblocking agents; dispersants such as calcium stearate; lubricants; nucleophiles; pigments; softeners; hydrophilic agents; water repellents; auxiliary agents; water repellents; fillers; antimicrobials; agricultural chemicals; insecticides; medicines; natural oil; and synthetic oil.
  • additives include a variety of the following additives: other polymers; colorants; antioxidants such as phosphorous or phenolic antioxidants; weathering stabilizers such as benzotriazole-based weathering stabilizers; light resistance stabilizers such as hindered amine-based light resistance stabilizers; antiblocking agents; dispersants such as calcium stearate;
  • stabilizers examples include: organophosphorous compounds such as tris(2,4-di-tert-butylphenyl)phosphite; hindered amine-based compounds such as decanedioic acid bis(2,2,6,6-tetramethyl-4-piperidinyl) and 2,4-dichloro-6-(1,1,3,3-tetramethylbutylamino)-1,3,5-triazine.N,N′-bis(2,2,6,6-tetramethyl-4-piperidyl)hexamethylenediamine polycondensate; and phenolic compounds such as 1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl)-butane.
  • organophosphorous compounds such as tris(2,4-di-tert-butylphenyl)phosphite
  • hindered amine-based compounds such as decanedioic acid bis(2,2,6,6-tetramethyl-4-piperidinyl)
  • stabilizers include: at least one hindered amine-based compound such as organophosphorous compounds of tris(2,4-di-tert-butylphenyl)phosphite, decanedioic acid bis(2,2,6,6-tetramethyl-4-piperidinyl), and 2,4-dichloro-6-(1,1,3,3-tetramethylbutylamino)-1,3,5-triazine.N,N′-bis(2,2,6,6-tetramethyl-4-piperidyl)hexamethylenediamine polycondensate; and phenolic compounds such as 1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl)-butane.
  • hindered amine-based compound such as organophosphorous compounds of tris(2,4-di-tert-butylphenyl)phosphite, decanedioic acid bis(2,2,6,6-tetramethyl-4-piperidinyl), and
  • Examples thereof further include: metal salts of fatty acid such as zinc stearate, calcium stearate, and 1,2-hydroxycalcium stearate; and polyalcohol fatty acid esters such as glycerin monostearate, glycerin distearate, pentaerythritol monostearate, pentaerythritol distearate, and pentaerythritol tristearate. It is also possible to use any combination of these examples.
  • metal salts of fatty acid such as zinc stearate, calcium stearate, and 1,2-hydroxycalcium stearate
  • polyalcohol fatty acid esters such as glycerin monostearate, glycerin distearate, pentaerythritol monostearate, pentaerythritol distearate, and pentaerythritol tristearate. It is also possible to use any combination of these examples.
  • fillers may be added: silica, diatomaceous earth, alumina, titanium oxide, magnesium oxide, pumice powder, pumice balloon, aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, dolomite, calcium sulfate, potassium titanate, barium sulfate, calcium sulfite, talc, clay, mica, asbestos, calcium silicate, montmorillonite, bentonite, graphite, aluminum powder, and molybdenum sulfide.
  • the spunbond nonwoven fabric of the invention may be a nonwoven fabric including a mixed fiber prepared by mixing a different type of fibers (e.g., fibers obtained from the propylene-based polymer (A) alone or fibers obtained from a different olefin-based polymer, polyester, or thermoplastic elastomer), in addition to fibers obtained from the propylene-based polymer composition described above, within the range not impairing the objectives of the invention.
  • a different type of fibers e.g., fibers obtained from the propylene-based polymer (A) alone or fibers obtained from a different olefin-based polymer, polyester, or thermoplastic elastomer
  • fibers forming the spunbond nonwoven fabric of the invention may be fibers including the above described propylene-based polymer composition alone, or may be composite fibers having a side-by-side or core-clad structure and including the propylene-based polymer composition within the range not impairing the objectives of the invention.
  • the cross-sectional shape of fibers forming the spunbond nonwoven fabric of the invention may be a circle shape, a polygonal shape such as a star, triangular, rectangular, or pentagonal shape, an ellipse shape, or a hollow shape.
  • an air permeability of the spunbond nonwoven fabric of the invention is determined by a JIS L 1096 (2010) Frazier type air permeability tester under flow rate conditions at a pressure differential of 125 Pa and a weight per unit area of 20 g/m2
  • the air permeability is 500 cm 3 /cm 2 /s or less, preferably 450 cm 3 /cm 2 /s or less, and more preferably 400 cm 3 /cm 2 /s or less.
  • the lower limit thereof is not particularly limited; however, it is 50 cm 3 /cm 2 /s or more, preferably 100 cm 3 /cm 2 /s or more, and more preferably 200 cm 3 /cm 2 /s or more.
  • the air permeability of the spunbond nonwoven fabric is within the above range, appropriate air permeation or barrier performance can be achieved.
  • the obtained spunbond nonwoven fabric has excellent strength.
  • the air permeability is within such range, as the spunbond nonwoven fabric of the invention has the above properties, it can be favorably used particularly for medical materials and the like.
  • the weight per unit area of the spunbond nonwoven fabric of the invention is preferably in a range of from 5 g/m 2 to 50 g/m 2 and more preferably in a range of from 10 g/m 2 to 25 g/m 2 .
  • the mean fiber diameter of fibers forming the spunbond nonwoven fabric of the invention is preferably in a range of from 5 ⁇ m to 30 ⁇ m.
  • the upper limit of the mean fiber diameter is more preferably 25 ⁇ m or less and still more preferably 20 ⁇ m or less.
  • the mean fiber diameter is 20 ⁇ m or less, fibers forming the nonwoven fabric are sufficiently thin, which can be favorably used particularly for medical materials and the like.
  • the lower limit of the mean fiber diameter is not particularly limited; however, in a case in which the mean fiber diameter is 10 ⁇ m or more, a nonwoven fabric having excellent strength can be obtained.
  • MD (machine direction) strength is preferably 20N or more and CD (cross machine direction) strength is 10N or more. More preferably, MD strength is 25N or more and CD strength is 15N or more. When the strengthes are within the above ranges, the nonwoven fabric is unlikely to be perforated or broken, which is preferable.
  • the absorbed dose means a radiation dose upon 1 joule energy absorption per kg, which is expressed by Gy.
  • Strength INDEX after electron beam irradiation at an absorbed dose of 45 kGy is preferably 10N or more, still more preferably 13N or more, and most preferably 18N or more.
  • the spunbond nonwoven fabric of the invention has the Strength INDEX within the above range, it has sufficiently excellent strength even after electron beam irradiation.
  • the spunbond nonwoven fabric of the invention has the Strength INDEX within the above range after electron beam irradiation, it has sufficiently excellent strength, and it can be favorably used particularly for medical materials and the like, which is preferable.
  • Strength INDEX in the invention means a value calculated by the following equation.
  • the spunbond nonwoven fabric of the invention can be manufactured by a known method of manufacturing a spunbond nonwoven fabric. Specifically, it can be manufactured by, for example, conducting spinning of the above propylene-based polymer composition from a spinning nozzle in advance, cooling long fiber filaments that have been spun out using a refrigeration fluid or the like, applying tension to the filaments using air to stretch and result in a certain level of fineness, and collecting the obtained filaments on a running collection belt, thereby obtaining a spunbond nonwoven fabric including the filaments that have accumulated to a certain thickness.
  • the accumulated web can be treated by interlacing treatment, if necessary.
  • interlacing method examples include a variety of methods such as a method of heat embossing treatment using a roll, a method of ultrasonic fusion; a method of interlacing fibers using water jet, a method of fusion in a hot air through system, and a method using a needle punch.
  • the spunbond nonwoven fabric of the invention it is preferable to treat the spunbond nonwoven fabric of the invention by partial thermal compression via embossing or the like in order to improve strength of the obtained spunbond nonwoven fabric and maintain well-balanced flexibility and air permeation.
  • the embossed area percentage (at a thermal compression site) is preferably in a range of from 5% to 30% and more preferably in a range of from 5% to 20%.
  • Examples of the impressed shape include a circle shape, an ellipse shape, an oval shape, a square shape, a diamond shape, a rectangle shape, a quadrangle shape, a quilt shape, a lattice shape, a testudinal shape, and a continuous shape based on any of such shapes.
  • the spunbond nonwoven fabric of the invention may be treated by gear processing, printing, coating, laminating, heat treatment, or secondary processing such as shaping processing, hydrophilic processing, water-repellent processing, or press processing within the range not impairing the objectives of the invention.
  • Secondary processing can be applicable to a nonwoven fabric layered body including the spunbond nonwoven fabric of the invention.
  • the spunbond nonwoven fabric of the invention may be treated by processing treatment such as water-repellent treatment, if necessary.
  • Processing treatment such as water-repellent treatment can be carried out via coating with a processing agent such as a fluorinated water repellent or forming of a nonwoven fabric by mixing a water repellent as an additive with a resin starting material in advance.
  • the amount of the attached water repellent (content) is adequately from 0.5% by mass to 5.0% by mass.
  • a method of imparting alcohol repellency is, for example, a method including attaching a fluorinated processing agent to the spunbond nonwoven fabric so that the amount of the attached fluorinated processing agent is from 0.01% by mass to 3% by mass.
  • a method of attaching the processing agent and a drying method is not particularly limited.
  • the method of adhering the processing agent include: a method including spraying the processing agent; a method including immersing the spunbond nonwoven fabric in a processing agent bath and squeezing the spunbond nonwoven fabric with a mangle; and a method including coating.
  • the drying method include: a method using a hot air dryer; a method using a tenter; and a method including bringing the spunbond nonwoven fabric into contact with a heating element.
  • the above processing treatment in a case in which the spunbond nonwoven fabric is used, for example, for a medical gown or the like, water, alcohol, or oil is unlikely to permeate through the spunbond nonwoven fabric. Thus, even in the case that alcohol disinfection is performed or attachment of blood or the like is occurred, high barrier performance is achieved.
  • the above processing can be applied to a nonwoven fabric layered body containing the spunbond nonwoven fabric of the invention.
  • an antistatic property may be imparted to the spunbond nonwoven fabric of the invention.
  • a method of imparting an antistatic property include a method of coating using an adequate agent of imparting an antistatic property (e.g., fatty acid ester or quaternary ammonium salt) and a method of forming a nonwoven fabric by mixing an adequate agent of imparting an antistatic property as an additive with a resin starting material.
  • the antistatic property is preferably set to a level of 1,000V or less at 20° C. in a 40% RH atmosphere in accordance with the method of JIS L1094C (provided that friction cloth is cotton cloth).
  • the antistatic property is preferably set to a level of 1,000V or less at 20° C. in an 40% RH atmosphere in accordance with the method of JIS L1094C (provided that friction cloth is cotton cloth).
  • the spunbond nonwoven fabric is used for a medical gown or the like.
  • the above processing can be applied to a nonwoven fabric layered body including the spunbond nonwoven fabric of the invention.
  • the spunbond nonwoven fabric of the invention can be applied to, for example, various materials such as general sanitary materials, living materials, industrial materials, and medical materials. Specifically, it can be favorably used as a material for ground fabrics of disposable diapers, sanitary napkins, and compresses, bed covers, and the like.
  • the spunbond nonwoven fabric of the invention may be used alone, it is preferable to layer the spunbond nonwoven fabric with other materials described below in order to impart other functions.
  • the spunbond nonwoven fabric of the invention is stable against even a radioactive ray such as an electron beam irradiated upon sterilization or disinfection.
  • a nonwoven fabric layered body of the spunbond nonwoven fabric of the invention and other materials can be favorably applied particularly to medical materials for gowns, caps, masks, isolation gown, patient clothes, drape, sheets, kurumu (sterile wrap), towels, and the like used in hospitals and the like, if necessary.
  • the spunbond nonwoven fabric of the invention has favorable post-processing properties such as a heat-sealing property, it can be applied to general living materials for deoxidants, pocket warmers, warm compresses, masks, CD (compact disc) cases, food wrapping materials, clothes covers, and the like.
  • the spunbond nonwoven fabric of the invention can be favorably used for vehicle interior materials and various backing materials. Since thin fibers constitute the spunbond nonwoven fabric of the invention, the spunbond nonwoven fabric of the invention can also be widely applied to filter materials for liquid filters, air filters, and the like.
  • the nonwoven fabric layered body in the first embodiment of the invention contains the above spunbond nonwoven fabric.
  • the nonwoven fabric layered body in the first embodiment of the invention can be formed by layering a material that is the same as or different from the spunbond nonwoven fabric of the invention, such as a nonwoven fabric or film, on at least one side of the spunbond nonwoven fabric for the purpose of, for example, imparting other functions (e.g., adjustment of the balance among uniformity, barrier performance, and air permeation, or weight saving).
  • a material that is the same as or different from the spunbond nonwoven fabric of the invention such as a nonwoven fabric or film
  • Examples of a material that can be layered on the spunbond nonwoven fabric of the invention include a short fiber nonwoven fabric and a long fiber nonwoven fabric.
  • fiber materials for these nonwoven fabrics include cellulosic fibers of cotton, cupra, and rayon; polyolefin-based fibers; polyamide-based fibers; and polyester-based fibers.
  • examples of these nonwoven fabrics include the following materials: other spunbond nonwoven fabrics which are the same as or different from the spunbond nonwoven fabric of the invention; melt blown nonwoven fabrics; wet nonwoven fabrics; dry nonwoven fabrics; dry pulp nonwoven fabrics; flash-spun nonwoven fabrics; and spread nonwoven fabrics.
  • the film examples include films of a polyolefin-based resin, a polyamide-based resin, and a polyester-based resin.
  • a polyolefin-based resin e.g., polyethylene glycol dimethacrylate copolymer
  • a polyamide-based resin e.g., poly(ethylene glycol)
  • a polyester-based resin e.g., poly(ethylene glycol)
  • One type of or two or more types of these materials can be selected and layered.
  • the spunbond nonwoven fabric of the invention, a melt blown nonwoven fabric, and the spunbond nonwoven fabric of the invention can be layered in that order, and a nonwoven fabric such as a dry nonwoven fabric can be further layered thereon.
  • short fibers used in the invention refers to fibers having a mean fiber length of about 200 mm or less.
  • long fibers refers to “continuous long fibers (continuous filaments)” described in, for example, the Nonwoven Fabrics Handbook (edited by INDA, Association of the Nonwoven Fabrics Industry, in the U.S., Japan Nonwovens Report, 1996), which are generally used in the art.
  • a known method can be used for forming the nonwoven fabric layered body in the first embodiment of the invention.
  • the method include: a method of interlacing using a needle punch, a water jet, or the like; a method of thermal fusion bonding via heat embossing, ultrasonic fusion, or the like; a method of adhesion using a variety of adhesives such as a hot melt adhesive and an urethane-based adhesive; a method of layering via resin extrusion laminating.
  • nonwoven fabric layered bodies exemplified above, in particular, a nonwoven fabric layered body containing a melt blown nonwoven fabric and the spunbond nonwoven fabric is preferable, and a nonwoven fabric layered body in which a melt blown nonwoven fabric and the spunbond nonwoven fabric are layered via partial thermal fusion bonding (thermal compression) is more preferable.
  • nonwoven fabric layered body of a melt blown nonwoven fabric and a spunbond nonwoven fabric which is one preferable embodiment of the nonwoven fabric layered body in the first embodiment of the invention.
  • nonwoven fabric layered body of a melt blown nonwoven fabric and a spunbond nonwoven fabric examples include nonwoven fabric layered bodies of: a melt blown nonwoven fabric/a spunbond nonwoven fabric; a spunbond nonwoven fabric/a melt blown nonwoven fabric/a spunbond nonwoven fabric; a spunbond nonwoven fabric/a melt blown nonwoven fabric/a melt blown nonwoven fabric/a spunbond nonwoven fabric; and a spunbond nonwoven fabric/a melt blown nonwoven fabric/a spunbond nonwoven fabric/a melt blown nonwoven fabric/a spunbond nonwoven fabric.
  • nonwoven fabric layered bodies the configuration of a spunbond nonwoven fabric/a melt blown nonwoven fabric/a spunbond nonwoven fabric is preferable, and in a case in which the nonwoven fabric layered body with such configuration is used for medical materials, it is preferable in terms of durability or the like.
  • the mean fiber diameter of fibers forming a melt blown nonwoven fabric is preferably in a range of from 0.1 ⁇ m to 10 ⁇ m, more preferably in a range of from 0.5 ⁇ m to 8 ⁇ m, still more preferably in a range of from 1 ⁇ m to 5 ⁇ m, and particularly preferably in a range of from 1 ⁇ m to 4 ⁇ m.
  • the mean fiber diameter is within the above range, the obtained melt blown nonwoven fabric has favorable uniformity and excellent barrier performance.
  • excellent strength, barrier performance, and uniformity after electron beam irradiation are achieved, which is preferable.
  • the weight per unit area of a melt blown nonwoven fabric is preferably in a range of from 1 g/m 2 to 30 g/m 2 , more preferably in a range of from 3 g/m 2 to 25 g/m 2 , still more preferably in a range of from 5 g/m 2 to 20 g/m 2 , still more preferably in a range of from 7 g/m 2 to 18 g/m 2 , and particularly preferably in a range of from 10 g/m 2 to 17 g/m 2 .
  • excellent flexibility and barrier performance are achieved.
  • excellent strength, barrier performance, and uniformity after electron beam irradiation are achieved, which is preferable.
  • the weight per unit area may be adjusted to preferably a range of from 0.5 g/m 2 to 5 g/m 2 and more preferably a range of from 0.5 g/m 2 to 3 g/m 2 .
  • Fibers forming a melt blown nonwoven fabric are not particularly limited.
  • the fibers preferably include fibers containing an ethylene-based polymer composition for the purpose of preventing reduction of strength and barrier performance after electron beam irradiation.
  • fibers forming a melt blown nonwoven fabric include fibers containing an ethylene-based polymer composition
  • each of a spunbond nonwoven fabric and a melt blown nonwoven fabric contains an ethylene-based polymer. Therefore, for example, a melt blown nonwoven fabric and a spunbond nonwoven fabric can be easily joined upon joining via heat embossing treatment or the like, and the obtained nonwoven fabric layered body has excellent inter-layer adhesion strength, which is also preferable.
  • the ethylene-based polymer composition is preferably an ethylene-based polymer composition containing an ethylene-based polymer (a) having a melt flow rate (MFR) of from 10 g/10 minutes to 250 g/10 minutes and an ethylene-based polymer wax (b) having a weight-average molecular weight (Mw) of from 400 to 15000 at an (a):(b) mass ratio of 90:10 to 10:90.
  • MFR melt flow rate
  • Mw weight-average molecular weight
  • Fibers of the above ethylene-based polymer composition containing the specific ethylene-based polymer (a) and the specific ethylene-based polymer wax (b) each falling within the relevant range at a specific mass ratio are obtained, thereby preventing reduction of strength and barrier performance upon electron beam irradiation and achieving a thin fiber diameter and remarkably excellent spinnability.
  • An ethylene-based polymer (a) that is a component of fibers forming a melt blown nonwoven fabric is a resin similar to the ethylene-based polymer (B) and it is a polymer mainly including ethylene such as an ethylene homopolymer or a copolymer of ethylene and a different ⁇ -olefin.
  • the density of the ethylene-based polymer (a) is preferably in a range of from 0.870 g/cm 3 to 0.990 g/cm 3 , more preferably in a range of from 0.900 g/cm 3 to 0.980 g/cm 3 , still more preferably in a range of from 0.910 g/cm 3 to 0.980 g/cm 3 , and most preferably in a range of from 0.940 g/cm 3 to 0.980 g/cm 3 .
  • the ethylene-based polymer (a) is a crystalline resin, which is manufactured and sold as a low-density polyethylene, a linear low-density polyethylene, a middle-density polyethylene, a high-density polyethylene, or the like.
  • Examples of a different ⁇ -olefin that is copolymerized with ethylene include ⁇ -olefins with 3 to 20 carbons such as propylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, and 1-eicosene.
  • These ethylene-based polymers may be used alone or a mixture of two or more types thereof may be used.
  • the melt flow rate (MFR 190 determined at a load of 2.16 kg and 190° C. in accordance with ASTM D1238) of the ethylene-based polymer (a) according to the invention is not particularly limited as long as a melt blown nonwoven fabric can be manufactured using the ethylene-based polymer (a). However, it is preferably in a range of from 10 g/10 minutes to 250 g/10 minutes, more preferably in a range of from 20 g/10 minutes to 200 g/10 minutes, and still more preferably in a range of from 50 g/10 minutes to 150 g/10 minutes.
  • the melt flow rate of the ethylene-based polymer (a) within the above range is desirable in terms of the obtained thin fiber diameter and spinnability.
  • polymers obtained by a variety of known manufacturing methods e.g., a high-pressure method and a middle- or low-pressure method using a Ziegler catalyst or a metallocene catalyst
  • a high-pressure method and a middle- or low-pressure method using a Ziegler catalyst or a metallocene catalyst can be used for the ethylene-based polymer (a).
  • An ethylene-based polymer wax (b) that is a component of fibers forming a melt blown nonwoven fabric is a resin similar to the ethylene-based polymer wax (C) and it has a molecular weight smaller than that of the ethylene-based polymer (a). That is, the ethylene-based polymer wax (b) is a wax-type polymer.
  • the ethylene-based polymer wax (b) is obtained by a manufacturing method similar to that for the ethylene-based polymer wax (C).
  • the weight-average molecular weight (Mw) of the ethylene-based polymer wax (b) is preferably in a range of from 400 to 15,000, more preferably in a range of from 1000 to 15000, still more preferably in a range of from 6,000 to 15,000, particularly preferably in a range of from 6000 to 10000, and most preferably in a range of from 6,500 to 10,000.
  • Mw weight-average molecular weight
  • the density of the ethylene-based polymer wax (b) is preferably from 0.890 g/cm 3 to 0.985 g/cm 3 , more preferably 0.910 g/cm 3 or more, still more preferably 0.930 g/cm 3 or more, still more preferably 0.950 g/cm 3 or more, and particularly preferably 0.960 g/cm 3 or more. In addition, it is preferably 0.980 g/cm 3 or less. In a case in which the ethylene-based polymer wax (b) having the density within the above range is used, an excellent property of being kneaded with the ethylene-based polymer (a) and excellent spinnability and temporal stability can be achieved, which is preferable. In addition, fibers are unlikely to be melted upon embossing thermal compression for layering the obtained melt blown nonwoven fabric with the spunbond nonwoven fabric, which is preferable.
  • the ethylene-based polymer composition used herein is preferably an ethylene-based polymer composition containing an ethylene-based polymer composition containing an ethylene-based polymer (a) and an ethylene-based polymer wax (b) at a mass ratio of the ethylene-based polymer (a):the ethylene-based polymer wax (b) of from 90:10 to 10:90 as described above.
  • the (a):(b) mass ratio is more preferably from 90:10 to 50:50, still more preferably from 90:10 to 60:40, and most preferably from 90:10 to 70:30.
  • fibers forming a melt blown nonwoven fabric fibers containing the propylene-based polymer (c) are also preferable.
  • fibers forming a melt blown nonwoven fabric contain the propylene-based polymer (c)
  • the melt blown nonwoven fabric preferably includes fibers containing the propylene-based polymer (c).
  • a propylene-based polymer (c) that is a component of fibers forming a melt blown nonwoven fabric is a resin similar to the propylene-based polymer (A) and it is a polymer mainly including propylene such as a propylene homopolymer or a copolymer of propylene and a small amount of an ⁇ -olefin.
  • Examples of an ⁇ -olefin that is copolymerized with propylene include an ⁇ -olefin with 2 carbons or more (other than 3 carbons) such as pentene and preferably an ⁇ -olefin with from 2 to 8 carbons (other than 3 carbons).
  • Specifically examples thereof include ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, and 4-methyl-1-.
  • One type of or two or more types of these ⁇ -olefins may be used.
  • the melting point (Tm) of the propylene-based polymer (c) is not particularly limited; however, it is favorably in a range of 125° C. or more, preferably in a range of 140° C. or more, still more preferably in a range of 155° C. or more, and particularly preferably in a range of from 157° C. to 165° C.
  • the melt flow rate (MFR 230 : ASTM D-1238; 230° C., load: 2160 g) of the propylene-based polymer (c) is not particularly limited as long as melt spinning of the propylene-based polymer (c) is possible; however, it is preferably from 10 g/10 minutes to 4000 g/10 minutes, more preferably from 50 g/10 minutes to 3000 g/10 minutes, and still more preferably from 100 g/10 minutes to 2000 g/10 minutes.
  • the mass ratio (Mw/Mn) of the weight-average molecular weight (Mw) and the number average molecular weight (Mn) of the propylene-based polymer (c) according to the invention is preferably form 1.5 to 5.0. More preferably, it is in a range of from 1.5 to 4.5 because favorable spinnability can be achieved and fibers having remarkably excellent fiber strength can be obtained.
  • Mw and Mn of the propylene-based polymer (c) according to the invention are value obtained by GPC measurement, which are determined under the following conditions. Note that Mw and Mn are calculated based on the conversion method described below by creating a calibration curve using a commercially available standard monodisperse polystyrene.
  • Solvent o-dichlorobenzene
  • Flow rate 1.0 mL/minute
  • Sample 0.10 mg/mL o-dichlorobenzene solution
  • the density of the propylene-based polymer (c) in the invention is preferably in a range of from 0.895 g/cm 3 to 0.915 g/cm 3 , more preferably in a range of from 0.900 g/cm 3 to 0.915 g/cm 3 , and still more preferably in a range of from 0.905 g/cm 3 to 0.910 g/cm 3 .
  • the density in the invention is a value obtained by measurement in accordance with the density gradient method of JIS K7112.
  • the weight-average molecular weight (Mw) after electron beam irradiation at an absorbed dose of 45 kGy is preferably 28.000 or more and particularly preferably 33,000 or more.
  • the weight-average molecular weight (Mw) can be determined by gel permeation chromatography (GPC) in accordance with a known method.
  • the methods described below can be used: (1) a method wherein the molecular weight before electron beam irradiation is set to a high level in advance for fibers of a propylene-based polymer having an increased molecular weight, thereby adjusting the weight-average molecular weight after electron beam irradiation to fall within the above range; (2) a method wherein fibers of a propylene-based polymer composition containing a stabilizer is used, thereby reduction in the molecular weight due to electron beam irradiation is prevented to adjust the weight-average molecular weight after electron beam irradiation to fall within the above range; (3) combined use of the method (1) and the method (2).
  • a stabilizer added as an additive deteriorates due to heat, which is likely to result in loss of the effects of preventing the molecular weight from decreasing upon electron beam irradiation, thereby causing reduction of strength or barrier performance.
  • a propylene-based polymer (c) containing the stabilizer described below having a molecular weight that allows stable spinning of thin fibers at a lowered temperature.
  • the weight-average molecular weight (Mw) of the propylene-based polymer (c) is preferably in a range of from 30,000 to 100,000, more preferably in a range of from 40,000 to 80,000, and still more preferably in a range of from 40,000 to 60,000.
  • the weight-average molecular weight of the propylene-based polymer (c) can be adjusted to the above preferable range through degradation of a propylene-based polymer having a weight-average molecular weight exceeding the above preferable range at high temperatures upon melting in an extruder or the like.
  • the weight-average molecular weight (Mw) can be determined by gel permeation chromatography (GPC) in accordance with a known method.
  • the fibers are favorably fibers of a propylene-based polymer composition containing a stabilizer as an additive.
  • At least one stabilizer selected from the group consisting of an organophosphorous compound, a hindered amine-based compound, and a phenolic compound. It is particularly preferable to add an organophosphorous compound. It is more preferable to add at least two types of stabilizers. It is still more preferable to add an organophosphorous compound and a hindered amine-based compound or to add an organophosphorous compound and a phenolic compound. It is particularly preferable to add, as stabilizers, an organophosphorous compound, a hindered amine-based compound, and a phenolic compound.
  • an organophosphorous compound is especially used as an antioxidant stabilizer (stabilizer).
  • an antioxidant stabilizer include trioctyl phosphite, trilauryl phosphite, tridecylphosphite, octyl-diphenyl phosphite, tris(2,4-di-tert-butylphenyl)phosphite, triphenyl phosphite, tris(butoxyethyl)phosphite, tris(nonylphenyl)phosphite, distearylpentaerythritol diphosphite, tetra(tridecyl)-1,1,3-tris(2-methyl-5-tert-butyl-4-hydroxyphenyl)butane diphosphite, tetra(C 12-15 mixed alkyl)-4,4′-isopropylidene-diphenyl diphosphite, tetra(C 12-15
  • One type of the above examples may be used alone or any combination of two or more types thereof may be used. Of these, tris(2,4-di-tert-butylphenyl)phosphite, tris(mono/di-mixed nonylphenyl)phosphite, and the like are preferably used.
  • the amount of the above organophosphorous compound to be used is favorably from 0.001 parts by mass to 3 parts by mass and preferably from 0.001 parts by mass to 1 part by mass with respect to 100 parts by mass of the polypropylene-based polymer.
  • a hindered amine-based compound among known compounds may be used as a light stabilizer (stabilizer).
  • a hindered amine-based compound may be used without particular limitation; however, a hindered amine-based compound having a structure in which each of hydrogens bonded to carbons at the second and sixth positions of piperidine is substituted with a methyl can be used.
  • decanedioic acid bis(2,2,6,6-tetramethyl-4-piperidinyl), 2,4-dichloro-6-(1,1,3,3-tetramethylbutylamino)-1,3,5-triazine.N,N′-bis(2,2,6,6-tetramethyl-4-piperidyl)hexamethylenediamine polycondensate, and the like are particularly preferably used.
  • the amount of the above hindered amine-based compound to be used is favorably from 0.001 parts by mass to 3 parts by mass and preferably from 0.001 parts by mass to 1 part by mass with respect to 100 parts by mass of the polypropylene-based polymer.
  • phenolic antioxidants include: less hindered-type phenolic antioxidants such as 1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl)-butane and 4,4′-butylidene-bis(3-methyl-6-t-butylphenol); semi hindered-type phenolic antioxidants such as 3,9-bis[1,1-dimethyl-2- ⁇ -(3-t-butyl-4-hydroxy-5-methylphenyl)propionyloxy ⁇ ethyl]-2,4,8,10-tetraoxaspiro[5,5]undecane; and hindered-type phenolic antioxidants such as tris(3,5-di-t-butyl-4-hydroxybenzyl)isocyanurate, n-octadecyl-3-(3′,5′-di-t-butyl-4′-hydroxyphen
  • the amount of the above phenolic compound to be used is favorably from 0.001 parts by mass to 3 parts by mass and preferably from 0.001 parts by mass to 0.5 parts by mass with respect to 100 parts by mass of a polypropylene-based polymer.
  • an organic or inorganic coloring pigment may be used in combination.
  • tris(2,4-di-tert-butylphenyl)phosphite that is an organophosphorous compound (A), decanedioic acid bis(2,2,6,6-tetramethyl-4-piperidinyl) or 2,4-dichloro-6-(1,1,3,3-tetramethylbutylamino)-1,3,5-triazine.N,N′-bis(2,2,6,6-tetramethyl-4-piperidyl)hexamethylenediamine polycondensate as a hindered amine-based compound (B), and 1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl)-butane as a phenolic compound (C).
  • A organophosphorous compound
  • At least one hindered amine-based compound selected from an organophosphorous compound of tris(2,4-di-tert-butylphenyl)phosphite, decanedioic acid bis(2,2,6,6-tetramethyl-4-piperidinyl), and 2,4-dichloro-6-(1,1,3,3-tetramethylbutylamino)-1,3,5-triazine.N,N′-bis(2,2,6,6-tetramethyl-4-piperidyl)hexamethylenediamine polycondensate, and a phenolic compound of 1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl)-butane.
  • the total amount of these stabilizers to be used is favorably from 0.01 parts by mass to 10 parts by mass and preferably from 0.03 parts by mass to 2 parts by mass with respect to 100 parts by mass of a polypropylene-based polymer.
  • the above stabilizers might deteriorate due to high temperature degradation, and therefore, in a case in which it is necessary to compensate a loss due to deterioration, the amount of the stabilizers to be used may be increased.
  • sulfur-based or phosphite ester-based antioxidants may benzoate-based, benzophenone-based, triazole-based, or nickel-based light stabilizers; other metal deactivators, antistatics, lubricants, mold release agents, oroganic or inorganic pigments, fillers, peroxides, foaming agents, flame retardants, nucleating agents, and gum components such as a propylene.ethylene-based copolymer gum and ethylene.butene-based copolymer gum.
  • the melt blown nonwoven fabric can be manufactured using the ethylene-based polymer composition or a propylene-based polymer composition containing the stabilizer by a known method of manufacturing a melt blown nonwoven fabric.
  • the melt blown nonwoven fabric can be manufactured by a melt blowing method including conducting melt kneading of an ethylene-based polymer composition or a propylene-based polymer composition containing the stabilizer using an extruder or the like and ejecting the melt kneading product from a spinneret having a spinning nozzle while blowing away the product by a rapid and highly humid aerial flow injected from the vicinity of the spinneret, thereby allowing self-adhesive microfibers to accumulate on a collection belt to form a web.
  • subsequent interlacing treatment may be carried out, if necessary.
  • Examples of a method of interlacing treatment of the accumulated web that can be used, if appropriate, include a variety of methods such as a method of heat embossing treatment using a roll, a method of ultrasonic fusion; a method of interlacing fibers using water jet, a method of fusion in a hot air through system, and a method using a needle punch.
  • a method of manufacturing a nonwoven fabric layered body of a melt blown nonwoven fabric and a spunbond nonwoven fabric is not particularly limited as long as a melt blown nonwoven fabric and a spunbond nonwoven fabric can be integrated to form a layered body thereby.
  • a method of manufacturing a two-layer layered body including allowing fibers obtained from an ethylene-based polymer composition obtained by a melt blowing method or a propylene-based polymer composition containing a stabilizer to directly accumulate on a preliminarily obtained spunbond nonwoven fabric so as to form a melt blown nonwoven fabric and then fusing the spunbond nonwoven fabric and the melt blown nonwoven fabric via heat embossing or the like.
  • a method of manufacturing a three-layer layered body including allowing fibers obtained from an ethylene-based polymer composition obtained by a melt blowing method or a propylene-based polymer composition containing a stabilizer to directly accumulate on a preliminarily obtained spunbond nonwoven fabric so as to form a melt blown nonwoven fabric, further allowing fibers formed by a spunbond method to directly accumulate on the melt blown nonwoven fabric so as to form a spunbond nonwoven fabric, and then fusing the spunbond nonwoven fabric and the melt blown nonwoven fabric via heat embossing or the like.
  • (C) A method of manufacturing a layered body, including superimposing a preliminarily obtained spunbond nonwoven fabric and a separately manufactured melt blown nonwoven fabric and fusing both nonwoven fabrics via heating and pressurization.
  • (D) A method of manufacturing a layered body, including adhering a preliminarily obtained spunbond nonwoven fabric and a separately manufactured melt blown nonwoven fabric using an adhesive such as a hot melt adhesive, a solvent-based adhesive, or the like.
  • a method of layering a spunbond nonwoven fabric and a melt blown nonwoven fabric via thermal fusion bonding may be a method of thermal fusion bonding of the entire contact face between both nonwoven fabrics or a method of thermal fusion bonding of a part of the contact face. It is preferable to fuse a part of the contact face of both nonwoven fabric layers by a method of heat embossing.
  • the fusion area embossed area percentage corresponding to the area impressed by an embossing roll
  • the nonwoven fabric layered body has an excellent balance among barrier performance, adhesion strength, and flexibility.
  • the embossing temperature depends on the line speed or bonding pressure upon embossing; however, it is generally in a range of from 85° C. to 150° C.
  • An example of a method other than a method of layering a spunbond nonwoven fabric and a melt blown nonwoven fabric via thermal fusion bonding is a method of layering a spunbond nonwoven fabric and a melt blown nonwoven fabric with an adhesive.
  • a hot melt adhesive used in this method include: resin-based adhesives such as vinyl acetate-based adhesives and polyvinyl alcohol-based adhesives; and gum-based adhesives such as styrene-butadiene-based adhesives and styrene-isoprene-based adhesives.
  • examples of a solvent-based adhesive include: gum-based adhesives such as styrene-butadiene-based adhesives, styrene-isoprene-based adhesives, and urethane-based adhesives; resin-based organic solvents or aqueous emulsion adhesives of vinyl acetate and vinyl chloride.
  • gum-based hot melt adhesives such as styrene-isoprene-based adhesives and styrene-butadiene-based adhesives are preferable in that texture characteristic to a spunbond nonwoven fabric can be maintained.
  • inter-layer peeling strength between a melt blown nonwoven fabric layer and a spunbond nonwoven fabric layer is preferably 0.1N or more and more preferably 0.5N or more. Most preferably, no peeling occurs.
  • a nonwoven fabric layered body in the second embodiment of the invention contains the melt blown nonwoven fabric described below.
  • a nonwoven fabric layered body in the second embodiment of the invention can be favorably applied to medical clothing and drapes.
  • a preferable embodiment of a nonwoven fabric layered body in the second embodiment of the invention is defined as the preferable embodiment of the nonwoven fabric layered body in the first embodiment of the invention described above.
  • the melt blown nonwoven fabric of the invention includes fibers of a propylene-based polymer composition containing the propylene-based polymer (c) and at least one stabilizer selected from the group consisting of an organophosphorous compound, a hindered amine-based compound, and a phenolic compound.
  • the stabilizer preferably includes an organophosphorous compound, more preferably includes two or more types of stabilizers, still more preferably includes an organophosphorous compound and a hindered amine-based compound or an organophosphorous compound and a phenolic compound.
  • the stabilizer particularly preferably includes an organophosphorous compound, a hindered amine-based compound, and a phenolic compound.
  • the nonwoven fabric layered body has excellent inter-layer adhesion strength.
  • the nonwoven fabric layered body itself has excellent strength.
  • the nonwoven fabric layered body also has excellent heat resistance.
  • the propylene-based polymer (c) contained in fibers forming the melt blown nonwoven fabric of the invention is defined as the propylene-based polymer (c) used for a melt blown nonwoven fabric of a nonwoven fabric layered body described above.
  • the preferable range thereof is the same as that of the propylene-based polymer (c).
  • the stabilizer contained in fibers forming the melt blown nonwoven fabric of the invention is defined as the stabilizer used for a melt blown nonwoven fabric of a nonwoven fabric layered body described above.
  • the preferable range thereof is the same as that of the stabilizer described above.
  • Ten test pieces each having a size of 10 mm ⁇ 10 mm were obtained from a nonwoven fabric obtained as a spunbond nonwoven fabric.
  • the fiber diameter was read to one decimal place by the ⁇ m using a Nikon ECLIPSE E400 microscope at a 20-fold magnification. The diameter was measured at any 20 points for each test piece to calculate the mean value.
  • Tensile strength (N/50 mm) and Strength INDEX were determined in accordance with JIS L 1906 for a nonwoven fabric or a nonwoven fabric layered body before electron beam irradiation and a nonwoven fabric or a nonwoven fabric layered body after electron beam irradiation at an absorbed dose of 45 kGy.
  • a test piece having 50 mm in width ⁇ 200 mm in length was obtained from a nonwoven fabric.
  • Tensile strength was determined using a tensile tester (Autograph AGS-J manufactured by Shimadzu Corporation) at an inter-chuck distance of 100 mm and a head speed of 300 mm/min: MD: 5 points; and CD: 5 points. The mean value was calculated to determine tensile strength (N/50 mm).
  • Strength INDEX was calculated by the following equation:
  • a test piece having a size of 150 mm (MD) ⁇ 150 mm (CD) was obtained from the nonwoven fabric.
  • water-resistant pressure of a nonwoven fabric layered body was determined in accordance with Method A specified in JIS L 1096 (low water pressure method). The water-resistant pressure was used as an index of water resistance (barrier performance).
  • the number of times of thread breaking upon spinning of the spunbond nonwoven fabric in each of the Examples was determined and evaluated based on the following classification.
  • melt spinning was conducted using a mixture of 80 parts by mass of an ethylene.1-hexene copolymer [Prime Polymer Co., Ltd.; product name: Evolue H SP50800P; density: 0.951 g/cm 3 ; MFR: 135 g/10 minutes] and 20 parts by mass of an ethylene-based polymer wax [Mitsui Chemicals, Inc.; product name: “Excelex 40800;” density: 0.980 g/cm 3 ; weight-average molecular weight: 6900; softening point: 135° C.] by a melt blowing method through ejecting a melt resin through a spinneret having a nozzle with 760 holes (0.4-mm ⁇ ) at a rate of 0.15 g/minute for a single hole so that microfibers were formed and allowed to accumulate on a collection face.
  • a melt blown nonwoven fabric (MB) having a weight per unit area of 20 g/m 2 was produced.
  • the spunbond nonwoven fabric (SB) was layered on both sides of the melt blown nonwoven fabric (MB) obtained above.
  • the layered body was processed by thermal fusion bonding at 110° C. and a linear pressure of 1 MPa via heat embossing (at an impressed area rate of 18%).
  • an SMS nonwoven fabric layered body having a three-layer structure was obtained.
  • Physical properties of the obtained SMS nonwoven fabric layered body were determined in the above manner. Table 1 shows the results.
  • Nonwoven fabrics were obtained in the manner described in Example 1 except that 2 parts by mass of an ethylene-based polymer wax [Mitsui Chemicals, Inc.; product name: “HI-WAX 110P;” density: 0.922 g/cm 3 ; weight-average molecular weight: 1200; softening point: 113° C.] were used for the propylene-based polymer composition, in addition to 100 parts by mass of the propylene homopolymer (PP) and 4 parts by mass of the high-density polyethylene (PE) used in Example 1. Physical properties of each obtained nonwoven fabric were determined in the above manner. Table 1 shows the results.
  • Nonwoven fabrics were obtained in the manner described in Example 2 except that (Mitsui Chemicals, Inc.; product name: “Excelex 48070B;” density: 0.900 g/cm 3 ; weight-average molecular weight: 9000; softening point: 98° C.) was used as the ethylene-based polymer wax. Physical properties of each obtained nonwoven fabric were determined in the above manner. Table 1 shows the results.
  • Nonwoven fabrics were obtained in the manner described in Example 1 except that the mass of the high-density polyethylene (PE) was changed to 8 parts by mass. Physical properties of the obtained nonwoven fabric were determined in the above manner. Table 1 shows the results.
  • PE high-density polyethylene
  • Nonwoven fabrics were obtained in the manner described in Example 2 except that the mass of the high-density polyethylene (PE) was changed to 8 parts by mass. Physical properties of the obtained nonwoven fabric were determined in the above manner. Table 1 shows the results.
  • PE high-density polyethylene
  • Nonwoven fabrics were obtained in the manner described in Example 5 except that (Mitsui Chemicals, Inc.; product name: “Excelex 40800”) was used as the ethylene-based polymer wax. Physical properties of each obtained nonwoven fabric were determined in the above manner. Table 1 shows the results.
  • thermoplastic resin composition was obtained by adding the following to 100 parts by mass of a propylene homopolymer [MFR: 1500 g/10 minutes, weight-average molecular weight (Mw): 54000]:
  • melt spinning was conducted by a melt blowing method through ejecting a melt resin through a spinneret having a nozzle with 760 holes (0.4-mm ⁇ ) at a rate of 0.15 g/minute for a single hole so that microfibers were formed and allowed to accumulate on a collection face.
  • a melt blown nonwoven fabric (MB) having a weight per unit area of 20 g/m 2 was produced.
  • the weight-average molecular weight (Mw) of the melt blown nonwoven fabric (MB) after electron beam irradiation at an absorbed dose of 45 kGy was 37400.
  • the spunbond nonwoven fabric (SB) was layered on both sides of the melt blown nonwoven fabric (MB) obtained above.
  • the layered body was processed by thermal fusion bonding at 120° C. and a linear pressure of 1 MPa via heat embossing (at an impressed area rate of 18%).
  • an SMS nonwoven fabric layered body having a three-layer structure was obtained.
  • Physical properties of the obtained SMS nonwoven fabric layered body were determined in the above manner. Table 1 shows the results.
  • Nonwoven fabrics were obtained in the manner described in Example 7 except that a melt blown nonwoven fabric (MB) was produced using only 100 parts by mass of a propylene homopolymer [MFR: 1500 g/10 minutes; weight-average molecular weight (Mw): 54000]. Physical properties of the obtained nonwoven fabric were determined in the above manner. Table 1 shows the results. The weight-average molecular weight (Mw) of the melt blown nonwoven fabric (MB) after electron beam irradiation at an absorbed dose of 45 kGy was 25,900.
  • Nonwoven fabrics were obtained in the manner described in Example 1 except that only 100 parts by mass of a propylene homopolymer (PP) was used. Physical properties of the obtained nonwoven fabric were determined in the above manner. Table 1 shows the results.
  • PP propylene homopolymer
  • Nonwoven fabrics were obtained in the manner described in Example 3 except that the mass of the high-density polyethylene (PE) was changed to 15 parts by mass and the mass of the ethylene-based polymer wax was changed to 1 part by mass. Physical properties of the obtained nonwoven fabric were determined in the above manner. Table 1 shows the results.
  • PE high-density polyethylene
  • Nonwoven fabrics were obtained in the manner described in Example 3 except that 4 parts by mass of (Prime Polymer Co., Ltd.; product name: “ULT-ZEX 20200J;” MFR: 18.5 g/10 minutes; density: 0.918 g/cm 3 ) was used as the high-density polyethylene and the mass of the ethylene-based polymer wax was changed to 2 parts by mass. Physical properties of the obtained nonwoven fabric were determined in the above manner. Table 1 shows the results.
  • Nonwoven fabrics were obtained in the manner described in Example 1 except that a spunbond nonwoven fabric was produced so that the fiber diameter was adjusted to 21 ⁇ m. Physical properties of the obtained nonwoven fabric were determined in the above manner. Table 1 shows the results.
  • SB denotes a spunbond nonwoven fabric
  • MB denotes a melt blown nonwoven fabric
  • SMS denotes a nonwoven fabric layered body of a spunbond nonwoven fabric/a melt blown nonwoven fabric/a spunbond nonwoven fabric
  • PP denotes a propylene-based polymer
  • PE denotes an ethylene-based polymer
  • wax denotes an ethylene-based polymer wax
  • - denotes lack of the relevant component in Table 1.
  • Example 1 For example, a comparison between Example 1 and Examples 2 and 5 revealed that spinnability is improved with the addition of an ethylene-based polymer wax. Further, it is understood that a nonwoven fabric layered body including a melt blown nonwoven fabric has excellent inter-layer adhesion strength.
  • Examples 1 to 6 and Examples 7 and 8 revealed that when fibers forming a melt blown nonwoven fabric include propylene-based polymer fibers, excellent inter-layer adhesion strength is achieved, and nonwoven fabric layered body strength is also favorable.
  • Example 7 in which a starting material of the melt blown nonwoven fabric is a stabilizer, water-resistant pressure was maintained at 500 mmH 2 O or more even after electron beam irradiation, meaning that deterioration in water-resistant pressure was prevented.

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US15/521,939 2014-10-30 2015-10-30 Spunbond nonwoven fabric, nonwoven fabric layered body, medical clothing, drape, and melt blown nonwoven fabric Abandoned US20170314174A1 (en)

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US10737459B2 (en) * 2016-12-14 2020-08-11 Pfnonwovens Llc Hydraulically treated nonwoven fabrics and method of making the same
TWI770366B (zh) * 2018-02-28 2022-07-11 日商東麗股份有限公司 紡黏不織布
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CN107075762B (zh) 2021-06-18
JP2020147890A (ja) 2020-09-17
EP3214216A4 (en) 2018-04-25
KR102146211B1 (ko) 2020-08-19
EP3214216A1 (en) 2017-09-06
CN113373599A (zh) 2021-09-10
JP6337137B2 (ja) 2018-06-06
CN107075762A (zh) 2017-08-18
JP6717876B2 (ja) 2020-07-08
JPWO2016068312A1 (ja) 2017-06-01
WO2016068312A1 (ja) 2016-05-06
KR20170065588A (ko) 2017-06-13
MY171630A (en) 2019-10-22
KR101962051B1 (ko) 2019-07-17

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